Breaking ERD Records with Optimized Engineering and Practices: Making the Impossible Possible

Long-extended reach drilling (ERD) well has become necessary to reach untapped resources. This paper will describe pre-planning, execution and post results of drilling ERD wells with large bore design of 12¼" as the main step out section and deploying 9⅝" casing on shallow TVD of 4,200’. Progressive increase of the ERD ratio and complexity from one well to the next was planned and executed till we reached the longest well deploying 8 KM of 9⅝" casing with 5.4 ERD ratio at 26,179' TD horizontally all the way. A learning curve was established on drilled wells while progressively increasing reach and complexity. Subject well was the longest of any well planned in the field by far. Success involved implementation of technically modeled engineered solutions and verified during execution. Operational procedures including but not limited to: proper planning and execution of well profile to ensure optimum placement in a specific formation and minimum side forces. Drilling and tripping procedures to ensure the lowest friction factor (FF) and allow drilling to target depth (TD) with optimum rig capability. Engineered solution for casing running technologies, which involved rotation and conventional running and floatation. The longest ERD well was drilled to 26,179' TD with field ROP record in 12¼" hole section, maintaining very good hole quality proved by smooth bit trips out of hole and the final trip at TD on elevators. Hole cleaning and fluids strategy was developed and executed efficiently to measure FFs as low as possible for successful 9⅝" deployment. Engineered solution was proposed for 9⅝" deployment and was successfully trial tested on a shorter well to validate simulations. Casing rotation FFs came close to the modeled FFs. The 9⅝" Casing was deployed to bottom as planned and the cement job was performed successfully. Various records were achieved: the subject well achieved the deepest 9⅝" horizontal casing, the deepest 12¼" horizontal at TVD shallower than 5,000'. The longest 12¼" horizontal open hole at TVD shallower than 5,000' with section footage of 16,164'. The 9⅝" casing was deployed as a long string, eliminating the cost and challenges of a liner hanger and the need for a future tieback and also keeping hole sizes available for main and contingency sections to drill the reservoirs ahead. In addition to existing developed procedures and practices for ERD wells, subject well was dealing with the challenge of drilling a long 12 ¼" hole with a torque limitation of 30K lbsf.ft on TDS, and 4200 psi on surface equipment, and running the longest casing horizontally at such a shallow TVD, which is being done the first time globally. The success proved that challenging ERD wells can be drilled with optimum investments on rig capabilities.

Advanced Engineering Solutions to Achieve Best in Class Performance in Drilling Extended Reach Dual Lateral Wells in the Sultanate of Oman

A Large Omani Operator successfully achieved best in class performance in drilling extended reach dual-lateral wells in Oman. Turning the legs to achieve the required separation distance and continue drilling to the required depth through a thin fractured reservoir resulted in complex well trajectories and harsh drilling environment. This paper will focus on the newly innovative designs, engineering optimizations and utilizing lean methodology to overcome drilling risks and achieve best in class performance. Rotary Steerable system was utilized to drill the extended reach drilling (ERD) in 3D with continuous proportional steering technology. Advance modeling including lateral shocks, Torque and Drag and BHA design were as well key enablers. Logging while drilling tools supported reservoir mapping and real-time well placement decisions. To excel in lateral applications and overcome harsh drilling environment, a shallow cone tip profile with High Performance cutter bit technology was selected. A focus optimization project using lean tools was performed to map out the undercut process, visualize possible waste, perform root causes analysis and implement countermeasures to eliminate the process waste Regional benchmark showed that the performance of 11 wells drilled since the start of the campaign is located within the best 10% of the benchmark data which is marked as best in class performance. Due to the continues improvement, the campaign manages to reach a learning curve of 30%. Furthermore, the actual production from the wells was 300% more than the forecast. Using the advanced RSS and bit technologies resulted in reducing the Torque values in the lateral section by 30% which effectively increased the reservoir drilled interval by 22%. The designed BHA also managed to complete wells including multi undercuts (up to 6) in one run. One trip Whipstock System for creating the second leg is used as part of the well design. The Whipstock system which is uniquely set in the horizontal tangent section has achieved 100% success rate in setting and retrieving operations. The undercut activities have improved by 50% as a direct result of the optimization Lean project. In addition, utilizing lean methodology resulted in reducing the cost impact of the additional sidetracks (undercuts) which enabled having best reservoir quality and achieving savings over the total cost of ownership TCO. Extended Reach Dual lateral well design was utilized for the first time in PDO operations during this drilling campaign. This paper will present how advance modelling can enable the industry to deliver complex well designs. Additionally, it will introduce the company innovation in implementing the Lean philosophy to optimize the drilling operation.

Value of Cement Bond Logs for Evaluation and Improvement of Cementing Practices in Extended Reach Drilling ERD Wells

This paper discusses the value of cement logs as the core input to analyze the cement quality and validate the improvements made to cementing designs and practices of the intermediate casing string in Extended-Reach Drilling (ERD) wells. The ERD wells are being drilled from artificial islands in a field offshore in the UAE. The primary cementing objectives are isolating the reservoirs from their sublayers and protecting the casing against possible future corrosion across an upper formation. Cementing challenges include higher angle deviation, higher mud weight requirements resulting from an anisotropic, unstable shale formation present above the reservoir section. Effective reservoir management requires sound zonal isolation to eliminate crossflow between different reservoir units. In combination with standard cement bond logs (CBL), ultrasonic technology has provided detailed information about cement quality and a qualitative indication of casing position in the borehole. These have also led to valuable insight into how continued cementing designs and practices improved zonal isolation. Improvements in cement quality seen as a result of enhanced casing centralization, optimized hydraulic model, modified cement rheology, displacement rate impact, among others, were confirmed with the cement log evaluation program. The paper will present the ultrasonic and standard CBL responses, which support the enhancements made to the cementing design and practices that yield the desired results. The cement quality has been improved in the ERD wells intermediate section through strategic modification in cementing practices. Cement evaluation logs have played a significant role in validating the cementing methods’ development. Consistently improved zonal isolation results have opened up the opportunity for future efficiency gains by eliminating routine CBL.

Enabling Extended Reach Wells with the Aid of an Ultra-High Speed Rotational Reamer Shoe

Well X is an infill horizontal well designed for the Gulf of Thailand. It is challenging due to the following factors - A long 8 ½ inch open hole section, An extended reach section at horizontal or near horizontal, the presence of loss circulation zones, an Extended Reach Drilling (ERD) ratio of 2.725 and a Drilling Difficulty Index (DDI) of 6.762. The key challenge was to successfully deploy the 7 inch casing across 12,350 ftMD of open hole, with potential loss circulation zones. In spite of these difficulties, the 7 inch casing was successfully landed with the use of an Ultra-High Speed Rotational Reamer Shoe. Historically, losses of circulation have posed significant challenges to well delivery in the Gulf of Thailand wells. In Well X, this is further complicated by a long open-hole section with a step-out of over 10,000 ftMD. It was determined that the successful deployment of the 7 inch casing would require some degree of agitation at the nose, and such a device must be tolerant to the Lost Circulation Materials (LCM) type and the composition of the drilling fluid and the cement. An ultra-high speed rotational reamer shoe was specially configured to meet the LCM requirements in the displaced fluid, for use in deploying the casing. While deploying the 7 inch casing, losses of up to 20 bbls/hr occurred from 7,043 ftMD while running at 15 joints/hr. A loss circulation recipe comprising of 60 bbls of 30 ppb Tiger LCM was mixed and successfully displaced through the customized ultra-high speed reamer shoe to cure losses. The casing was washed down from 10,569 to 11,610 ftMD, filling casing each stand. The 7 inch casing was successfully landed at the target depth of 12,353 feet and subsequently cemented. Drill out operations took 1.5 hours to complete. A formation integrity test (FIT) showed good shoe strength which was later confirmed by the cement evaluation logs. The comprehensive Ultra-High Speed Reamer Shoe was configured with a minimum restriction of 15mm, which is 5 times the diameter of the maximum particle size in the LCM of 3 mm. The tool was designed to tolerate the prescribed loss circulation materials, making it possible to cure the losses while running the casing string. The innovative Ultra-High Speed Reamer Shoe has demonstrated its usefulness by providing a higher probability for successfully deploying the 7 inch production casing over the extended reach section of Well X. The application of this technology can mitigate against non-productive time such as wiper trips or excessive washing down or casing rotation. It has proven to be a reliable technology that can be used in the industry in challenging well designs.

Remote Reservoir Exploration in Odoptu-More Field by Delivering ERD Wells Using Multilateral Drilling Technology

This paper provides the results that were achieved and shares the drilling unique practices that were implemented to deliver the first complex bilateral extended reach drilling (ERD) well in Odoptu-more field (North Dome). Well design driven by geological objectives considered drilling 215.9mm main and pilot holes (PH). Well complexity was governed by the type of a profile having ERD ratio of 5.22 (main hole) / 4.60 (PH) and trajectory's 3D nature (turn in azimuth of 90 degrees) compared to previous wells in the project drilled mainly with 2D profiles. Apart from the problems connected with drilling and casing upper sections key challenges comprised kicking off in 215.9mm open hole at 5955m MD and 1512m TVD with rotary steerable system, setting cement plugs at shallow true vertical depth (TVD) at 89 degrees of inclination to abandon laterally drilled PH, delivering 168.3mm production liner to bottom with a risk of entering a lateral while running in hole. An effective collaboration between integrated engineering team and customer departments went far beyond ERD standard set of operations already existing in the project thus allowing to break its own records and to set new achievements due to integrated technological approach. The longest 444.5mm section (2975 m) was drilled in one run achieving the record daily drilling rate and rate of penetration (ROP). Cementing of 244.5mm floated liner resulted in the highest good cement bond integrity percentage ever achieved among other wells in project due to new ways of casing standoff and fluid rheology hierarchy modeling. For the first time in the project 215.9mm main horizontal hole in extreme reach ERD well has been drilled by kicking off in open hole from the pilot horizontal one with push-the-bit rotary steerable system without a kickoff plug with pilot hole being abandoned by setting cement plugs. Project-specific risk assessment conducted by team allowed successful deployment of 168.3mm liner into the main hole. Moreover, due to thorough engineering planning electrical submersible pump (ESP) was run without extending 244.5mm liner to surface by tie-back thus saving additional 7 days. Drilling first bilateral ERD well unlocked opportunities for the operator to reach, explore and develop different extended geological targets thus eliminating well construction process of additional wells on drilling upper sections.

Buoyancy Force on a Plain or Perforated Portion of a Pipe

Summary Torque and drag models have been used for several decades to calculate tension and torque profiles along drillstrings, casing strings, and liner strings. Buoyancy forces contribute to the loads acting on the pipe and affect its interaction with the borehole wall. Torque and drag calculations account for these localized effects, as well as the material internal forces, torques, and moments on each side of the contact. When the analysis is applied to a discrete length of pipe, the cross sections at each end do not contribute to the buoyancy forces because they are not in contact with the fluid, except where there is a change in diameter or at the end of the string of pipe. We argue that it is important to check that the models used for solid pipe torque and drag calculations remain valid for sand screens, in particular, the extent to which the buoyancy forces acting on a perforated tube might differ from those on a solid pipe. Because the buoyancy force is the result of the pressure gradient acting on the surface of the pipe, the presence of holes may also influence the buoyancy force. We propose that there are theoretical differences between local buoyancy forces acting on plain or perforated tubes. This paper describes how to calculate the local buoyancy force on a portion of a drillstem by the application of Gauss’ theorem and accounting for the necessary corrections arising from the cross sections not being exposed to the fluid. We built an experimental setup to verify that the tension inside a pipe subject to buoyancy behaves in accordance with the derived mathematical analysis. With complex well construction operations, for instance during extended-reach drilling or when drilling very shallow wells with high buildup rates, the slightest error in torques and drag calculations may end up jeopardizing the chances of success of the drilling operation. It is therefore important to check that the basis of design calculations remain valid in those contexts and that, for instance, sand screens or slotted liners may be run in hole safely after a successful drilling operation.

First Managed Pressure Cementing with 7" Liner Overcoming a Challenging ERD Well Offshore Madura

ZX is a development well located in offshore Madura, Indonesia. ZX is classified as an Extended Reach Drilling (ERD) well with 2.40 ERD ratio. ZX well is in KX field which known to have several drilling hazards. The formation has multiple lost circulation zones below the 9 5/8" casing shoe that is prone to total and partial losses due to combination depleted formation in the upper side and the nature of karst or fractured carbonate formation in middle and lower part of the interval. In addition, the bottom part of the hole section has problematic wellbore instability. These hazards lead to the necessity to closely monitor and control the pressure profile throughout the operation to find balance between loss circulation and wellbore stability to ensure an efficient and safe operation. An automated MPD system is used to precisely control bottom hole pressure. MPD system was used to drill 8-1/2" section of ZX well smoothly to target depth and geological objective was achieved without NPT. MPC was performed successfully for 7" liner cementing. This was the first MPC operation in offshore Madura and the application mitigated the loss circulation and avoided the unnecessary remedial cementing job. The paper will share the success story of MPD application in drilling narrow window ERD well in offshore Madura, Indonesia. It aims to describe the application of MPD for this specific ERD case from planning phase to execution phase as well as the lesson learned.

Extended-Reach Drilling Hits Mainstream To Squeeze Difficult Reservoirs

Though expensive and complex, extended-reach drilling (ERD) is moving more into the mainstream as the industry is driven to develop frontier reserves in fragile environments like the Arctic where drilling from shore to off-shore targets reduces a project’s infrastructure costs and environmental footprint. A form of directional drilling, ERD is also being used increasingly to tap into hard-to-produce reservoirs, making viable projects that might otherwise be written off as noncommercial. This article highlights how the Russian Far East became the ERD epicenter in the past decade, given ExxonMobil and Rosneft’s extensive use of ERD in developing Arctic resources offshore Sakhalin Island, and how ERD is becoming more widely used in regions as diverse as the Gulf of Thailand, off-shore Brazil, and the Arab Gulf. By definition, an extended-reach well (ERW) is one in which the ratio of the measured depth (MD) vs. the true vertical depth (TVD) is at least 2:1 (PetroWiki). An ERW differs from a horizontal well in that the ERW is a high-angle directional well drilled to intersect a target point, a feat requiring specialized planning to execute well construction. ExxonMobil subsidiary Exxon Neftegas Limited (ENL), which operates the Sakhalin-1 license area offshore Russia’s Sakhalin Island (Fig. 1), has been pushing the limits of ERD for nearly 2 decades with innovative technologies and sophisticated well planning, making the Sea of Okhotsk a place where any ERD drilling record set today may easily be broken tomorrow. Russia’s state-owned Rosneft (which has a 20% stake in Sakhalin-1) owns bragging rights for having drilled the longest ERW well on record to date. Rosneft announced in November 2017 it had drilled a 15000-m horizontal ERW from the offshore Orlan gravity-base platform at Chayvo field situated in 14 m water depth in the Sea of Okhotsk, topping four previous records set between 2013 and 2015 that had reached between 12450 m and 13500 m (Fig. 2). In a news release at the time, Rosneft called the well “super complex with a DDI [directional drilling index] of 8.0 and a 14129-m stepout.” The release went on to say that the Sakhalin-1 Consortium could (as of the 2017 announcement) claim to have drilled nine out of the world’s 10 longest ERD wells. According to Rosneft, the project had set five world records for measured depth of wells between 2013 and 2017. In April 2015, development well O-14 was drilled with a length of 13500 m. That broke a 2014 record when the 13000-m Z-40 well was completed. In 2013, records were announced for wells Z-43 and Z-42 which were drilled, respectively, in April and in June 2013 with lengths of 12450 m and 12700 m. Rosneft credited ExxonMobil’s patented “Fast Drill” drilling optimization process that can increase rates of penetration (ROP) by up to 400% as a significant innovation contributing to the ERD success story at Sakhalin-1. One of the largest foreign direct investments in Russia, Sakhalin-1 operates under a production sharing agreement (PSA) with its license area off the northeastern coast of Sakhalin Island, comprising the Chayvo, Odoptu, and Arkutun Dagi fields.

Extended Reach Drilling with Coiled Tubing: A Case Study on the Alaskan North Slope That Proves the Benefits of Drilling a Straight Hole

Summary A set of five wells were to be drilled with directional coiled tubing drilling (CTD) on the North Slope of Alaska. The particular challenges of these wells were the fact that the desired laterals were targeted to be at least 6,000 ft long, at a shallow depth, almost twice the length of laterals that are regularly drilled at deeper depths. The shallow depth meant that two of the five wells involved a casing exit through three casings, which had never been attempted before. After drilling, the wells were completed with a slotted liner, run on coiled tubing (CT). This required a very smooth and straight wellbore so that the liner could be run as far as the lateral had been drilled. In this paper, we focus on one of the two wells on which triple casing exit was performed. However, the same considerations and results apply to the other wells on which the same technology has been used. Various methods were considered to increase lateral reach, including running an extended reach tool, using a friction reducer, increasing the CT size, and using a drilling bottomhole assembly (BHA) that could drill a very straight well path. All of these options were modeled with tubing forces software, and their relative effectiveness was evaluated. The drilling field results easily exceeded the minimum requirements for success. This project demonstrated record-breaking lateral lengths, a record length of liner run on CT in a single run, and a triple casing exit. The data gained from this project can be used to fine-tune the modeling for future work of a similar nature.

Best Practice to Improve Slim Hole Maximum Reservoir Contact Well Drilling Performance

Reservoir sections in MRC (Maximum Reservoir Contact) & ERD (Extended Reach Drilling) wells are mainly designed to drill 8 ½" hole, because of drilling limitations with smaller hole size. However, slim hole sizes offer opportunities to revitalize existing wells using re-entry drilling techniques in association with MRC and ERD designs. This paper discusses the best practices to be implemented in order to mitigate risk, reduce complexity and ensure improved drilling performance. Re-Entry wells in the field have a risk of well integrity issues such as corroded 9 5/8" casing. In order to mitigate this risk, the corroded 9 5/8" casing should be covered by 7" liner & tied-back to surface before drilling reservoir section. In this situation up to 18,000 ft of 4" DP is used in the wells to drill 6" hole and run 4 ½" lower completion. Offset well analysis, whip stock selection criteria, BHA design, drilling fluid selection, drilling and tripping practices based on torque & drag and hydraulics calculations are most important to achieve the well objective. The Slim hole MRC well was completed without any issues and achieved good drilling performance. It was observed that the actual drilling parameters such as torque, drag and stand pipe pressure were less than simulated parameters. NAF was selected in the section to reduce the friction factor, while motorized RSS and a reamer stabilizer were used in the BHA to reduce torque, drag and ensure a smooth well profile. A back reaming practice was implemented in hole section to reduce dog leg severity and the open hole was eventually displaced to viscosified brine to minimize the friction factor for running the 4 ½' lower completion. 8500 ft of 6" hole section was drilled and TD was reached at +/- 19,000ft within 50 days including recovering the existing completion, drilling 8 ½" & 6" hole and running completion. This paper aims to contribute to the oilfield industry by sharing the successfully implemented engineering design and operation execution methodology to overcome the complexities present in Re Entry Wells MRC/ERD wells required to be drilled with slim hole conditions under an optimal cost, time effectiveness and low risk.